Insulating Panel with Staggered Perforations to Reduce Thermal Bridges
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Solution Overview
Problem
Current insulating panels in air-flow casings, such as those used in air handling units, suffer from thermal bridges due to mechanical assemblies, leading to inefficient thermal insulation and increased outer wall temperatures, which can result in thermal losses and fail to meet product certification standards.
Innovation Solution
An insulating panel design featuring an inner and outer metal sheet with a layer of insulating material and a peripheral edge comprising staggered rows of perforations, which interrupt thermal conduction paths, reducing thermal bridges and outer wall temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical assembly is used to fasten insulating panels to the air handling unit structure, then structural strength and panel fixation are improved, but thermal bridges are created leading to increased thermal losses
Solution Approach 1:
The patent introduces an intermediary thermal break element between the metal sheets and the structural framework. This intermediary layer interrupts the direct thermal conduction path while maintaining mechanical attachment, thereby reducing thermal bridges without compromising structural strength.
Solution Approach 2:
The patent applies different thermal insulation properties to different regions of the panel assembly. Specifically, the peripheral edges and fastening areas incorporate enhanced thermal break features, while the central insulation core maintains standard properties, optimizing thermal performance where it is most needed.
2Ease of manufacture
If standard insulating panels without perforations are used, then manufacturing simplicity is maintained, but thermal conduction along peripheral edges remains high creating thermal bridges
Solution Approach 1:
The patent segments the continuous peripheral edge of the insulating panel by introducing periodic perforations. This segmentation interrupts the thermal conduction path along the edge while maintaining the overall structural integrity and insulation performance, effectively reducing thermal bridges with minimal impact on manufacturing.
3Loss of energy
If dense rows of perforations are added to the peripheral edge, then thermal conduction is reduced, but manufacturing complexity and production time increase
Solution Approach 1:
The patent applies partial perforation rather than complete edge perforation. By providing perforations at strategic intervals along the peripheral edge rather than continuous perforation, the solution achieves sufficient thermal break performance while keeping manufacturing complexity and production time acceptable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The staggered perforations in the insulating panel effectively mitigate thermal conduction, reducing thermal losses and ensuring compliance with thermal insulation standards by creating a thermal baffle that lengthens and disrupts heat transfer paths between the inner and outer walls.
Implementation Method 1
the perforations of the second row are placed with respect to the first row of perforations in a staggered manner... the edge of the panel is interrupted by perforations which mitigate thermal conduction towards the outer wall
Data Source
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AI summary
This insulating panel (4) for an insulated air-flow casing (2) comprises an inner sheet (46) forming an inner wall (40), an outer sheet (48) fastened to the inner sheet (46) and forming an outer wall (44), a layer of insulating material (50) placed between the inner and outer sheets (46, 48), and a peripheral edge (42) extending transversally between the inner wall (40) and the outer wall (44). The peripheral edge (42) comprises at least a first and a second rows (52a, 52b) of perforations (52), and the perforations (52) of the second row (52a) are placed with respect to the first row (52a) of perforations in a staggered manner.